System and method for forming an article

ABSTRACT

A fusing system includes an upper member and a base member. The upper member includes a pressing layer and the base member is associated with a last member. The pressing layer has a contoured portion that approximates the shape of a portion of the last member. The upper member can be associated with the base portion and a vacuum can be applied so that the pressing layer is pulled down onto materials disposed on the last member for purposes of fusing the materials together to form articles, such as articles of footwear.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.13/773,729, titled “System and Method For Forming An Article” and filedFeb. 22, 2013, which application is incorporated by reference herein.

BACKGROUND

The present embodiments relate generally to footwear and in particularto a method of making footwear and an associated system.

Articles of footwear generally include two primary elements: an upperand a sole structure. The upper is often formed from a plurality ofmaterial elements (e.g., textiles, polymer sheet layers, foam layers,leather, synthetic leather) that are stitched or adhesively bondedtogether to form a void on the interior of the footwear for comfortablyand securely receiving a foot. More particularly, the upper forms astructure that extends over instep and toe areas of the foot, alongmedial and lateral sides of the foot, and around a heel area of thefoot. The upper may also incorporate a lacing system to adjust the fitof the footwear, as well as permitting entry and removal of the footfrom the void within the upper. In addition, the upper may include atongue that extends under the lacing system to enhance adjustability andcomfort of the footwear, and the upper may incorporate a heel counter.

The sole structure is secured to a lower portion of the upper so as tobe positioned between the foot and the ground. In athletic footwear, forexample, the sole structure may include a midsole and an outsole. Themidsole may be formed from a polymer foam material that attenuatesground reaction forces (i.e., provides cushioning) during walking,running, and other ambulatory activities. The midsole may also includefluid-filled chambers, plates, moderators, or other elements thatfurther attenuate forces, enhance stability, or influence the motions ofthe foot, for example. The outsole forms a ground-contacting element ofthe footwear and is usually fashioned from a durable and wear-resistantrubber material that includes texturing to impart traction. The solestructure may also include a sockliner positioned within the upper andproximal a lower surface of the foot to enhance footwear comfort.

Various components of an article of footwear can be formed usingmultiple materials and/or material layers. Uppers, for example, maygenerally be formed by combining multiple layers, such as one or morebase layers and various trim layers.

SUMMARY

In one aspect, a system for making articles of footwear includes a basemember and a last member attached to the base member, the last memberhaving the approximate geometry of a foot. The system also includes apressing layer, where a portion of the pressing layer has a geometrythat is approximately similar to the geometry of the last member. Thepressing layer is configured to wrap around the last member andmaterials disposed on the last member when a vacuum is applied betweenthe base member and the pressing layer.

In another aspect, a system for making articles of footwear includes abase member and a last member attached to the base member, the lastmember having the approximate geometry of a foot. The system alsoincludes a pressing layer, the pressing layer including an outwardsurface and an inward surface disposed opposite of the outward surface.The pressing layer includes a concave portion with respect to theoutward surface and the concave portion is configured to receive thelast member. The pressing layer can flex when a vacuum is appliedbetween the base member and the pressing layer.

In another aspect, a system for manufacturing articles includes an uppermember including a cavity, the upper member being further associatedwith a pressing layer that extends into the cavity. The system alsoincludes a base member configured to associate with the upper member,where associating the upper member with the base member provides a sealin the region between the pressing layer and the base member. Thepressing layer includes a contoured portion and the pressing layer canbe used to apply pressure to at least two materials that may be placedbetween the pressing layer and the base member.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic isometric view of an embodiment of a fusing systemfor articles of footwear;

FIG. 2 is a schematic isometric exploded view of some components of afusing system;

FIG. 3 is a schematic isometric exploded view of some components of anupper member of a fusing system;

FIG. 4 is a schematic isometric view of a pressing layer for a fusingsystem;

FIG. 5 is a schematic cross-sectional view of an embodiment of a fusingsystem;

FIG. 6 is a schematic isometric view of an embodiment of various layersfor an upper of an article of footwear;

FIG. 7 is a schematic isometric view of the layers of FIG. 6 temporarilyattached to one another;

FIG. 8 is a schematic isometric view of an embodiment of an upper memberbeing lowered onto a base member of a fusing system;

FIG. 9 is a schematic cross-sectional view of an embodiment of thefusing system of FIG. 8 once the upper member is lowered onto the basemember;

FIG. 10 is a schematic cross-sectional view of the fusing system of FIG.9 once a vacuum has been applied between a pressing layer and the basemember;

FIG. 11 is a schematic cross-sectional view of the fusing system of FIG.10, in which heat is applied to the system;

FIG. 12 is a schematic cross-sectional view of the fusing system of FIG.9, in which the system is cooled;

FIG. 13 is a schematic isometric view of an embodiment of a resultingupper for an article of footwear created using fusing system 100; and

FIG. 14 is a schematic isometric view of an alternative embodiment for afusing system configured for use in making hats.

DETAILED DESCRIPTION

FIG. 1 is a schematic isometric view of an embodiment of a fusing system100. Fusing system 100 may be used to apply pressure and/or heat tomaterials on a three-dimensional last. In some embodiments, fusingsystem 100 may be intended for use with various kinds of articlesincluding articles of footwear and/or articles of apparel. Fusing system100 may be used for a variety of purposes, including for example, fusingtwo or more materials together using pressure and/or heat. One suchmethod for fusing materials together to form portions of an article offootwear is disclosed in Berend et al., U.S. Patent ApplicationPublication Number 2014/0237853, “Bottom Down Last for 3D Forming”, theentirety of which is hereby incorporated by reference. Moreover, fusingsystem 100 may be used to fuse materials together while the materialsare disposed on a three-dimensional form, such as a last. This allowsthe materials to be joined in a manner that accommodates the contours ofthe final three-dimensional article.

In other embodiments, fusing system 100 may have other implementations.As another example, fusing system 100 may be used to transfer graphicsfrom a transfer layer to a portion of an article using pressure and/orheat. One such example of a graphic transfer method that uses pressureand heat is disclosed in Hull, U.S. Pat. No. 8,162,022, issued Apr. 24,2012, the entirety of which is hereby incorporated by reference.Therefore, it will be understood that the fusing system 100 of theembodiments discussed below may be utilized for a variety of differentpurposes where it may be necessary to apply pressure and/or heat overportions of an article (i.e., footwear and/or apparel). Moreover, theprovisions described to facilitate fusing, bonding, graphic transfer,material shaping, as well as a variety of other functions may be usefulwith three-dimensional/contoured as well as substantially flat articles.

For clarity, the following detailed description discusses embodimentswhere a fusing system is used to apply pressure and/or heat to anarticle of footwear. Generally, a fusing system can be used with anykinds footwear including, but not limited to: hiking boots, soccershoes, football shoes, sneakers, rugby shoes, basketball shoes, baseballshoes, running shoes as well as other kinds of shoes. While theembodiments in the figures show a single article, it will be understoodthat a fusing system could be used with two or more articles, includingarticles that make up a pair of footwear.

A fusing system need not be limited to use with articles of footwear andthe principles taught throughout this detailed description may beapplied to additional articles as well. Generally, these principlescould be applied to any article kinds of articles. Examples of articlesthat can be used with the fusing system include, but are not limited to:footwear, gloves, shirts, pants, socks, scarves, hats, jackets, as wellas other articles. Other examples of articles that may be used include,but are not limited to: shin guards, knee pads, elbow pads, shoulderpads, as well as any other type of protective equipment. Additionally,in some embodiments, the article could be any other type of article,including, but not limited to: balls, bags, purses, backpacks, as wellas other articles. Moreover, the article may be any article that can beworn or may be an article that is not generally worn.

As seen in FIG. 1, fusing system 100 may include a base member 110 and acorresponding upper member 120. Base member 110 generally comprises thelower part of fusing system 100, while upper member 120 may comprise theupper part of fusing system 100. As described in further detail below,base member 110 and upper member 120 may correspond in a manner thatallows upper member 120 to interface with base member 110. In someembodiments, upper member 120 may interface with base member 110 in amanner that provides a fluid tight seal between the two members.

In some embodiments, base member 110 may comprise a platform likeportion. In some embodiments, the geometry of base member 110 may beapproximately rectangular, though in other embodiments the geometrycould vary. In some embodiments, base member 110 includes a raisedcentral portion 112, which rises from a peripheral portion 114.

In some embodiments, base member 110 may further include an interfacemember 130. In some embodiments, interface member 130 may be disposed onraised central portion 112. Interface member 130 may be integrallyformed with base member 110 or may be separably attached to base member110. Moreover, interface member 130 may include further provisions forconnecting base member 110 and last member 150, which is discussed infurther detail below.

In some embodiments, upper member 120 may comprise a block-like portionwith a lower side 122 that confronts base member 110. In someembodiments, lower side 122 may further include a central cavity 124 ofupper member 120 that is concave with respect to a lower peripheralsurface 126. Furthermore, the size and geometry of central cavity 124may be such that central raised portion 112 of base member 110 fits intocentral cavity when upper member 120 is lowered onto base member 110.

Generally, central cavity 124 can have any shape. In some embodiments,central cavity 124 may have a substantially box-like shape so thatcentral cavity 124 has a substantially constant depth. In otherembodiments, central cavity 124 could have an irregular shape. Forexample, in some embodiments, central cavity 124 could have a shape thatcorresponds approximately to the shape of a footwear last. In stillother embodiments, central cavity 124 could have any other shapeincluding, but not limited to: a rounded shape, a polyhedral shape, aregular shape, an irregular shape, a symmetric shape, an asymmetricshape as well as any other shape.

Some embodiments of upper member 120 may further include a pressinglayer 160. In some embodiments, pressing layer 160 may extend across alower region 170 of central cavity 124. In some embodiments, pressinglayer 160 may extend across the entirety of central cavity. Thus, insome embodiments, pressing layer 160 may generally separate a loweropening 172 of central cavity 124 from an interior chamber 174 (see FIG.5). In some cases, interior chamber 174 may be bound by pressing layer160 and interior cavity walls 176 of central cavity 124 (see FIG. 5).

FIG. 2 illustrates a schematic view of an embodiment of base member 110.Referring now to FIGS. 1 and 2, fusing system 100 may be furtherassociated with last member 150. In embodiments intended for use witharticles of footwear, last member 150 may comprise a footwear last thathas the approximate geometry of a foot. Last member 150 may beconfigured to receive portions of an article of footwear, such as afootwear upper, as well as materials used in the construction of thearticle of footwear (e.g., materials for making an upper). Although thecurrent embodiment illustrates a footwear last, other embodiments couldincorporate lasts for other kinds of articles including any articlesdescribed above. As an example, in an alternative embodiment, a lastcould have the geometry of a head (or portion of a head) to accommodatethe manufacturing of hats and/or other headwear.

In different embodiments, last member 150 may include various provisionsto hold materials in place and/or heat materials disposed on last member150. In some embodiments, for example, last member 150 could include oneor more airflow holes. Airflow holes may be utilized in a variety ofmanners, including, providing suction along the surface of last member150 to hold portions of material in place on last member 150.Additionally, in some cases, holes could be used to circulate air frominside last member 150 to the materials along the outer surface of lastmember 150. Such a use of airflow holes may allow heat emanating fromelements inside last member 150 to be transferred efficiently tomaterials on last member 150. Embodiments may use any of the systems,components, devices and/or methods as disclosed in Fisher et al., U.S.Patent Application Publication Number 2014/0223671, “Last withRetractable Pins”, the entirety of which is hereby incorporated byreference and hereafter referred to as the retractable pin case.Although some embodiments may incorporate airflow holes, otherembodiments may not include any airflow holes.

For purposes of illustration, the embodiment shown in FIG. 1 illustratesa plurality of airflow holes 159. In this embodiment, plurality ofairflow holes 159 are localized in the toe region of last member 150.However, it will be understood that in other embodiments, airflow holescan be arranged in any pattern and/or configuration over any portion oflast member 150. Other embodiments, for example, could include asubstantially even distribution of airflow holes over a majority of lastmember 150. Others could include sets of airflow holes selectivelyplaced in various regions to facilitate suction as well as heatingand/or cooling of various sections of material.

In some embodiments, last member 150 could include provisions formechanically holding portions of material in place. For example, someembodiments may incorporate one or more retractable pins that facilitatethe alignment of material on last member 150. Moreover, the retractablepins may retract inwardly into last member 150 once a component (such aspressing layer 160) contacts the pins, thereby reducing the tendency ofthe pins to puncture or otherwise damage the contacting component. Theembodiments can use any of the retractable pin systems and/orconfigurations disclosed in the retractable pin case cited above.

In some embodiments, interface member 130 may provide a means ofreleasably connecting last member 150 to base member 110. In someembodiments, interface member 130 may include first positioning pin 202and second positioning pin 204. First positioning pin 202 and secondpositioning pin 204 may be configured to insert into first receivingslot 206 and second receiving slot 208, respectively, which are locatedon bottom surface 152 of last member 150. In some cases, first receivingslot 206 and second receiving slot 208 are sized and shaped so thatfirst positioning pin 202 and second positioning pin 204 may be insertedinto wider portions of first receiving slot 206 and second receivingslot 208, respectively, but may include more narrow portions thatprevent the vertical release of first positioning pin 202 and secondpositioning pin 204. This arrangement allows last member 150 to beplaced vertically down onto interface member 130 and then translatedlongitudinally to lock first positioning pin 202 and second positioningpin 204 in place relative to the vertical direction, thereby preventingunwanted removal of last member 150 from base member 110.

Although the current embodiment uses two positioning pins, otherembodiments could use one, two, three or more than three positioningpins. Moreover, the pins could be configured in any arrangement.Moreover, in other embodiments, any other kinds of fasteners known inthe art could be used to releasably secure a last member to interfacemember 130.

The arrangement described here allows for last members to be releasablyattached to a fusing system. In some embodiments, two or more lastmembers may be used in an interchangeable manner with a fusing system.For example, some embodiments could utilize different interchangeablelast members to accommodate differences in article orientations (i.e.,left/right), article sizes (i.e., size 8, size 9, size 10, etc.) and/orarticle styles (i.e., low-top, high-top, etc.).

In some embodiments, fusing system 100 may include one or more thermalelements. The term “thermal element” as used throughout this detaileddescription and in the claims refers to any component, device or systemconfigured to change the thermal properties of a portion of fusingsystem 100. For example, in one embodiment, fusing system 100 comprisesa first thermal element 220 and a second element 222 in the form ofheating and cooling pipes. In particular, first thermal element 220 andsecond element 222 extend outwardly from base member 110, throughinterface member 130 and into last member 150. More specifically, firstthermal element 220 extends through first interface hole 230 (see FIG.5) and into first last hole 240. Likewise, second thermal element 222extends through second interface hole 232 (see FIG. 5) and into secondlast hole 242. Thus, before or after last member 150 is assembled withinterface member 130, first thermal element 220 and second thermalelement 222 may be inserted into corresponding holes of last member 150.

In operation, first thermal element 220 and second thermal element 222may act to heal and/or cool last member 150. In some embodiments, firstthermal element 220 and second thermal element 222 are airflow pipesthat facilitate the transfer of hot and/or cool air from aheating/cooling source (not shown).

In some embodiments, fusing system 100 may include provisions forcreating a vacuum within last member 150 and/or in the regionsurrounding last member 150. In some embodiments, interface member 130incorporates a first vacuum aperture 260 and a second vacuum aperture262. First vacuum aperture 260 and second vacuum aperture 262 may be influid communication with a corresponding first vacuum channel 270 andsecond vacuum channel 272, respectively, of base member 110 (see FIG.5). First vacuum channel 270 and second vacuum channel 272 may befurther connect to a vacuum source (not shown), such as a vacuum pump.

In some embodiments, first vacuum aperture 260 and second vacuumaperture 262 may confront a first vacuum hole 280 and a second vacuumhole 282, respectively, disposed on bottom surface 152 of last member150. In particular, with last member 150 in position on interface member130, first vacuum hole 280 and second vacuum hole 282 may be in fluidcommunication with first vacuum aperture 260 and second vacuum aperture262. This arrangement allows a vacuum to be generated within the hollowinterior 154 (see FIG. 5) of last member 150. In particular, inembodiments utilizing one or more airflow holes (such as plurality ofairflow holes 159 shown in FIG. 1) along the outer surface of lastmember 150, this arrangement may create an inward pressure or suctionalong outer surface 156 of last member 150. In some embodiments, firstvacuum aperture 260 and/or second vacuum aperture 262 may be in fluidcommunication with the region between pressing layer 160 and base member110, so that as a vacuum is generated, air within this region can bedirectly evacuated through first vacuum channel 270 and second vacuumchannel 272.

In some embodiments, to facilitate the mounting of last member 150 to afusing system, an additional layer of material may be provided betweenlast member 150 and interface member 130. In some embodiments, fusingsystem 100 may further include an intermediate layer 290. In some cases,intermediate layer 290 may be a substantially thin layer of silicone.Thus, as pressing layer 160 wraps around the upper and side surfaces oflast member 150, pressing layer 160 and intermediate layer 290 may actto substantially surround or enclose last member 150 (as well asmaterials disposed on last member 150). This arrangement may facilitateheating/cooling and/or may enhance the vacuum pressure applied aroundlast member 150 by pressing layer 160.

FIG. 3 illustrate a schematic exploded isometric view of upper member120 while FIG. 4 illustrates a schematic isometric top down view ofpressing later 160. Referring to FIGS. 3 and 4, pressing layer 160includes a substantially flat peripheral portion 302 and a contouredcentral portion 304. More specifically, the geometry of contouredcentral portion 304 is concave relative to an outward surface 310 (orlower surface) of pressing layer 160 (see FIG. 3) and convex relative toan inward surface 312 (or upper surface) of pressing layer 160 (see FIG.4). In some embodiments, a cavity 320 of contoured central portion 304is configured to receive a last member (such as last member 150).

As clearly seen in FIG. 4, contoured central portion 304 has a geometrythat approximates the top of a footwear last. Contoured central portion304 may include a forefoot portion 330, a midfoot portion 332, a heelportion 334 and an ankle portion 336, which all generally correspond toregions of a footwear last, such as last member 150. Moreover, thiscontoured shaped is maintained as long as pressing layer 160 is notsubjected to any external forces, such as various air or other fluidpressures.

In some embodiments, pressing layer 160 may be made of a substantiallyflexible, elastic and/or deformable material. Thus, pressing layer 160may be configured to stretch, bend, twist, and/or otherwise flex ordeform in a manner that differs from the default geometry shown in FIG.4. In some cases, the degree of flexibility can be selected so thatpressing layer 160 can flex around last member 150 when subjected tovarious pressures within fusing system 100. In some embodiments, under apredetermined amount of pressure, pressing layer 160 may flex enough toconform tightly to the shape of last member 150. Moreover, as thepressure is released, pressing layer 160 may return to the defaultgeometry once again.

In different embodiments, pressing layer 160 could comprise a variety ofdifferent materials. In some embodiments, pressing layer 160 maycomprise a layer of silicone material. However, other embodiments couldutilize any other materials that are substantially flexible and/ordeformable. The type of material used for pressing layer 160 may beselected according to various factors including desired flexibility,desired elasticity, desired thermal conduction properties, desireddurability as well as possibly other factors.

One possible means for attaching pressing layer 160 within upper member120 is shown in FIG. 3. In this embodiment, upper member 120 maycomprise a body portion 360 and a lower frame portion 362. Peripheralportion 302 of pressing layer 160 may be pressed between body portion360 and lower frame portion 362. Moreover, the fastening of lower frameportion 362 to body portion 360 can be accomplished using any kinds offasteners, including, but not limited to: screws, bolts, nails, rivetsas well as any other kinds of fasteners known in the art.

The embodiments shown in FIGS. 3 and 4 include a pressing layer shapedto accommodate a last member of a predetermined shape. In otherembodiments, however, the geometry of a pressing layer may vary toaccommodate last members of different geometries. For example, lastscorresponding to high-tops and low-tops may require the use of pressinglayers having corresponding geometries. Likewise, embodiments using alast for other kinds of articles (i.e., a head-shaped last for a hat ora torso-shaped last for a shirt) may require the use of pressing layerswith corresponding geometries that differ from the geometries of FIGS. 3and 4. Some other exemplary geometries are discussed in further detailbelow.

FIG. 5 illustrates a cross-sectional view of various components offusing system 100. Referring to FIG. 5, the similarity of the geometryof pressing layer 160 and last member 150 can be clearly seen. Inparticular, pressing layer 160 comprises various contours thatapproximately correspond with various contoured portions of last member150. Thus, it can be clearly seen that pressing layer 160 is pre-shapedor pre-configured to associate with last member 150.

Using a pressing layer with a pre-shaped geometry may help reduce thetendency of the pressing layer to tug, pull or otherwise applyundesirable forces to material layers as the upper member is lowered tothe base member. Moreover, in some cases, a pre-shaped geometry mayreduce ripping, tearing or other undesired permanent deformations of thepressing layer prior to the application of the vacuum to deform thepressing layer to the last member.

FIGS. 6 through 13 illustrate an exemplary method of using fusing system100 to form an upper for an article of footwear, in which the resultingupper is formed from at least a base layer and two trim layers. Forpurposes of clarity, only some possibly materials and/or layers used inthe construction of an upper are shown and in other embodiments, anyother materials, layers and/or other provisions could be used.

FIGS. 6 and 7 illustrate schematic isometric views of materials that maybe used with fusing system 100 in order to create an upper for anarticle of footwear. Specifically, as seen in FIGS. 6 and 7, a baselayer 602 may be associated with a first trim layer 604 and a secondtrim layer 606. In this embodiment, first trim layer 604 may beconfigured to cover and/or reinforce the region associated with eyelets608 of base layer 602. Second trim layer 606 may be associated with atoe portion of base layer 602. For purposes of illustration, two trimlayers are shown here, however in other embodiments any number of layerscould be used. Moreover, the layers may be trim layers, or any otherkinds of layers which may improve functionality and/or modify theoverall material characteristics of the resulting upper.

In order to facilitate fusing, in some embodiments, first trim layer 604and/or second trim layer 606 may be temporarily fixed in place on baselayer 602. In some cases, first trim layer 604 and/or second trim layer606 may be temporarily attached to base layer 602 using, but not limitedto, any of the following methods: temporary adhesives, welding(including ultrasonic welding), various kinds of fasteners (i.e., pins,clips, etc.), as well as possibly other provisions.

FIG. 8 illustrates a schematic isometric view of fusing system 100, inwhich base layer 602, first trim layer 604 and second trim layer 606have all been placed onto last member 150. At this point, upper member120 may be lowered onto base member 110.

FIG. 9, shows a cross-sectional view of fusing system 100 once uppermember 120 has been lowered onto base member 110. In some embodiments,pressing layer 160 may initially be spaced apart from base layer 602,first trim layer 604 and second trim layer 606. In some cases, thisarrangement may help reduce the tendency of pressing layer 160 to causeone or layers to be misaligned prior to the application of a vacuum. Inother embodiments, pressing layer 160 may be in contact with one or moreof these layers.

Referring next to FIG. 10, with upper member 120 in position on basemember 110, vacuum pressure can be used to pull pressing layer 160tightly against last member 150 as well as base layer 602, first trimlayer 604 and second trim layer 606. In particular, a vacuum (indicatedschematically by arrows within first vacuum channel 270 and secondvacuum channel 272) created between pressing layer 160 and base member110 may cause pressing layer 160 to conform to the contours of lastmember 150. Moreover, as seen in FIG. 11, in some embodiments heat mayalso be applied using first thermal element 220 and second thermalelement 222. In FIG. 11 the heating of interior 154 of last member 150due to the inflow of hot air is indicated schematically by thermometer650. The resulting heat and pressure may cause first trim layer 604 andsecond trim layer 606 to be permanently bonded, or fused, to base layer602.

In some embodiments, the pressure of cavity 174 could also be adjusted.For example, in some cases, the pressure of cavity 174 could beincreased using an external pressure source. As the pressure withincavity 174 is increased, pressing layer 160 may be further pressedagainst last member 150 and corresponding layers of material. Thus, insome cases, this increase in pressure in cavity 174 may increase theforce with which pressing layer 160 is applied across the surface oflast member 150 and the overlying materials. The embodiments may use anyof the systems, devices, components and/or methods for applying externalpressure forces to a flexible membrane in a cavity that are disclosed inFisher et al., U.S. Patent Application Publication Number 20140239556,“System and Method for Applying Heat and Pressure to Three-DimensionalArticles,” the entirety of the document being incorporated by referenceherein.

In some embodiments, as seen in FIG. 12, following the application ofheat and pressure, the vacuum pressure may be released so that pressinglayer 160 returns to a default state (i.e., default geometry). In someembodiments, to facilitate cooling of the resulting upper, cool air canbe circulated within last member 150 through first thermal element 220and second thermal element 222. In FIG. 12, the cooling of interior 154of last member 150 is indicated schematically by thermometer 650.

As seen in FIG. 13, upper member 120 may be lifted from base member 110so that the resulting upper 700 can then be removed from last member150. Upper 700 may comprise permanently fused layers that may remainattached under various types of stresses applied to upper 700 when upper700 is worn. In some embodiments, upper 700 may be further associatedwith a sole structure or similar component in order to create a finishedarticle of footwear.

As previously described, some embodiments could include pressing layerswith different pre-defined or default geometries corresponding todifferent shaped lasts. FIG. 14 illustrates an alternative pressinglayer geometry that may be used with a last for forming hats. Referringto FIG. 14, first pressing layer 802 may have a geometry thatapproximately corresponds with the geometry of last member 804, which islast for making hats. In this embodiment, for example, hat 810 may befused with a panel of material 812 by placed hat 810 onto last member804 and pressing it with pressing layer 802 using the previouslydescribed methods and systems.

While various embodiments of the embodiments have been described, thedescription is intended to be exemplary, rather than limiting and itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the embodiments. Accordingly, the embodiments are not to berestricted except in light of the attached claims and their equivalents.Also, various modifications and changes may be made within the scope ofthe attached claims.

What is claimed is:
 1. A method for making articles of footwear,comprising: placing a base layer and at least one additional layer on afirst surface of a last member, wherein the last member has a geometryof a foot and has a hollow interior; pulling a pressing layer againstthe base layer, the at least one additional layer, and the first surfaceof the last member by creating a vacuum between the pressing layer andthe last member; flowing, via an airflow heating pipe, and while thepressing layer is pulled against the base layer, hot air into the hollowinterior of the last member, wherein the airflow heating pipe extendsinto a first portion of the hollow interior; and removing the base layerand the at least one additional layer from the last member after the atleast one additional layer has fused to the base layer.
 2. The method ofclaim 1, wherein the last member is attached to a base member, andwherein a portion of the pressing layer has a geometry that is similarto the geometry of the last member.
 3. The method of claim 2, whereinthe airflow heating pipe extends outwardly from the base member and intothe first portion of the hollow interior.
 4. The method of claim 3,wherein a second airflow heating pipe extends outwardly from the basemember and into a second portion of the hollow interior.
 5. The methodof claim 1, wherein the pressing layer includes a flat outer peripheralportion and a contoured central portion.
 6. The method of claim 5,wherein the last member is attached to a base member, wherein thepressing layer is attached to an upper member, and wherein the uppermember is lowered onto the base member.
 7. The method of claim 6,wherein the upper member includes a cavity configured to receive thecontoured central portion of the pressing layer.
 8. The method of claim1, wherein the last member comprises a plurality of airflow holes thatprovide fluid communication between the hollow interior and an outersurface of the last member.
 9. The method of claim 1, wherein the lastmember is attached to a base member, wherein an interface member isdisposed on the base member and the last member is attached to theinterface member, wherein the interface member includes a first vacuumaperture that is in fluid communication with a first vacuum channelextending through the base member, and wherein creating the vacuumbetween the pressing layer and the last member comprises applying avacuum through a first vacuum hole formed on a bottom surface of thelast member.
 10. The method of claim 9, wherein the first vacuum holeconfronts the first vacuum aperture such that the first vacuum hole isin fluid communication with the first vacuum aperture.
 11. The method ofclaim 9, wherein the interface member includes at least a firstpositioning pin that is inserted into a first receiving slot formed inthe last member.
 12. The method of claim 9, wherein the interface memberincludes at least a first positioning pin, and wherein the last memberincludes a first receiving slot formed in a bottom surface of the lastmember that engages the first positioning pin.
 13. The method of claim1, wherein the last member is attached to a base member, and wherein thepressing layer is disposed within an upper member, and furthercomprising: lowering the upper member onto the base member to seal aregion between the pressing layer and the base member.
 14. The method ofclaim 1, further comprising circulating cool air within the hollowinterior.
 15. The method of claim 1, wherein the last member isreleasably attached to a base member.